Zinc Rich Epoxy Primer Workshop

Transcription

1 National Shipbuilding Research Program Zinc Rich Epoxy Primer Workshop Ingalls Shipbuilding September 4, 2014 NSRP Surface Preparation & Coatings Panel Approved for public release; distribution is unlimited.

2 Agenda Introduction Ingalls Shipbuilding Perspective Losset Supplier Overview International Paint - Winter PPG Paint Morrissey Previous Research Elzly Technology Study Ault BREAK NRL Study TBD Discussion of Tech. / Env. Issues NAVSEA Perspective - Ingle Actions and Way Forward Group

3 Ingalls Shipbuilding Perspective What Change is Requested? What is the Rationale? Summary of Goals 3

4 What Change is Requested? Request: NAVSEA to approve this statement for all ship classes and platforms: Zinc rich epoxy primer with extended overcoat window may be applied, unless otherwise specifically prohibited, as the first coat of epoxy primer in lieu of other epoxy primers Critical coated areas, and other areas as designated by NAVSEA, would be specifically prohibited. 4

5 What is an Extended Overcoat Window? 5 Information taken from EPA 75V Product Data Sheet

6 Marine Painting Guide Overcoating Interval The product data sheet gives both a minimum and a maximum overcoating interval and the figures quoted at the various temperatures are intended as guidelines, consistent with good painting practices. Certain terms require elaboration as follows: N/A Information taken from International Paint Marine Painting Guide 6

7 What is the Rationale? Rationale: Affordability / Cost Reduction Improved Shipyard HS&E Proven Performance Successful Experience / Low Risk 7

8 Affordability / Cost Reduction Affordability Factors: Less labor (abrading) Less labor (repairs) Less consumable materials Fewer coats of paint Fewer inspections Commonality economies Recoat Abrade Blast Clean Prime Magnitude of Abrading Step Potential for Cost Reduction Across Programs 8

9 Affordability / Cost Reduction Less work to grind back and feather Backside Burn Damage Backside Burn Damage 9

10 Improved Shipyard HS&E Zinc Rich Epoxy Primer reduces: Dust emissions Damage to sensitive equipment Impact on other craft Debris removal Special ventilation requirements 10 Zinc Rich Epoxy Primer Does not require sanding, just clean before next coat Legacy Epoxy Primer Requires 100% sanding by hand or with power tools after 30 days

11 Proven Performance No performance issues Easy to spray; fast dry Easier to maintain during construction; less susceptible to damage and easier to feather Anti-corrosive performance is better than epoxy (but less than ethyl silicate inorganic zinc primers) 11

12 Cost & Weight Impact Comparison of cost and weight: Legacy and Zinc Rich Epoxy Paint Solids per TDS (%) Typical DFT (Mils) Practical Coverage at Typical Mils (sqft) Gals Required per Million (sqft) Material Cost (%) Weight (lb/gal) Weight of Film (lb/gal) Dry Film Weight per Million (sqft) MIL-DTL Legacy Epoxy Epoxy Primer Primer , ,226 Zinc Rich Epoxy Primer , ,469 Legacy Epoxy Primer Legacy Epoxy Primer 12

13 Successful Experience / Low Risk LPD 18 (partial) LPD 20 LPD 21 LPD 23 LPD 25 LPD Plus: All USCG and MSC ships and most ships afloat today throughout the world

14 Summary of Goals Reduce ship construction cost and improve shipyard HS&E by expanding the use of zinc rich epoxy primers. Specific recommendations: 1. Short Term Action: NAVSEA to allow zinc rich epoxy primers with extended overcoat windows on all Navy classes Proposal from Ingalls to be submitted by the end of September 2. Long Term Action: NAVSEA to establish a new MIL-SPEC Type for qualification of epoxy primers with extended overcoat windows The NSRP SPC Panel Project: Universal Primer and Surface Preparation Process, if selected by the ECB, could be used to develop comparative data on new epoxy primer candidates. 14

15 Approved for public release; distribution is unlimited.

16 BACKUP SLIDES

17 Performance Extend/Standardize Approval to Use Zinc Rich Epoxy Primer (International Interzinc 75v) to All Programs Elzly Technology Corporation Report Study supports change Coating is mature technology used in similar applications Can meet the pertinent aspects of the relevant specification Will result in lower application cost and better performance May result in reduced maintenance cost Removal cost to be determined by others 17

18 Performance 18

19 Other Issues - Potential Competitive Products 19

20 Life Cycle Environmental 20 Source : PSDSRA Heavy Metals Subcommittee Author - Dewey Youngerman-CMSD Draft Dated - September 19, 2013

21 Life Cycle Environmental NAVSEA Perspective 21

22 Life Cycle Environmental Navy reports surcharges up to $16.50 / sqft for zinc coating removal in San Diego. Waste Disposal Waste disposal is apparently NOT the cause of excess charges sect Consider marine paint/nonskid to contain heavy metals (e.g., lead, cadmium, or chromium), hexavalent chromium, crystalline silica and/or other toxic or hazardous substances. Abatement Abatement is the apparent trigger for excess charges by repair contractors OSHA zinc exposure limit is the same as nuisance dust Status SURFPAC rep has stated belief that contractor misinterpreted CA toxicity regs. Litigation is underway to recover excess charges 22

23 Other Issues - Cleaning NAVSEA / SOS have concerns that SP-1 cleaning is not clearly defined and is hard to inspect (that is, to tell if it has been accomplished) Production process is in place and has been successfully implemented on 10 ships. NAVSEA TWH has stated that there are no known system failures 23